US20220037555A1 - Micro light emitting diode, array substrate, display apparatus, and method of fabricating array substrate - Google Patents
Micro light emitting diode, array substrate, display apparatus, and method of fabricating array substrate Download PDFInfo
- Publication number
- US20220037555A1 US20220037555A1 US16/762,922 US201916762922A US2022037555A1 US 20220037555 A1 US20220037555 A1 US 20220037555A1 US 201916762922 A US201916762922 A US 201916762922A US 2022037555 A1 US2022037555 A1 US 2022037555A1
- Authority
- US
- United States
- Prior art keywords
- electrode
- layer
- doped semiconductor
- type doped
- semiconductor layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000758 substrate Substances 0.000 title claims abstract description 255
- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 239000004065 semiconductor Substances 0.000 claims abstract description 253
- 238000000034 method Methods 0.000 claims description 50
- 229910052751 metal Inorganic materials 0.000 claims description 40
- 239000002184 metal Substances 0.000 claims description 40
- 239000000463 material Substances 0.000 claims description 36
- 238000005530 etching Methods 0.000 claims description 22
- 239000007772 electrode material Substances 0.000 claims description 18
- 239000010409 thin film Substances 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 5
- 230000002093 peripheral effect Effects 0.000 claims description 4
- 230000008569 process Effects 0.000 description 7
- 239000013256 coordination polymer Substances 0.000 description 6
- JMASRVWKEDWRBT-UHFFFAOYSA-N Gallium nitride Chemical compound [Ga]#N JMASRVWKEDWRBT-UHFFFAOYSA-N 0.000 description 4
- 230000001154 acute effect Effects 0.000 description 4
- 238000009616 inductively coupled plasma Methods 0.000 description 4
- 238000001020 plasma etching Methods 0.000 description 4
- 229910002601 GaN Inorganic materials 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- KZBUYRJDOAKODT-UHFFFAOYSA-N Chlorine Chemical compound ClCl KZBUYRJDOAKODT-UHFFFAOYSA-N 0.000 description 2
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 2
- 239000000460 chlorine Substances 0.000 description 2
- 229910052801 chlorine Inorganic materials 0.000 description 2
- 238000000708 deep reactive-ion etching Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- FAQYAMRNWDIXMY-UHFFFAOYSA-N trichloroborane Chemical compound ClB(Cl)Cl FAQYAMRNWDIXMY-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000001312 dry etching Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010884 ion-beam technique Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 229910052594 sapphire Inorganic materials 0.000 description 1
- 239000010980 sapphire Substances 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- TXEYQDLBPFQVAA-UHFFFAOYSA-N tetrafluoromethane Chemical compound FC(F)(F)F TXEYQDLBPFQVAA-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
- H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
- H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
- H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
- H01L24/81—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a bump connector
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/93—Batch processes
- H01L24/95—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0062—Processes for devices with an active region comprising only III-V compounds
- H01L33/0075—Processes for devices with an active region comprising only III-V compounds comprising nitride compounds
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
- H01L33/04—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a quantum effect structure or superlattice, e.g. tunnel junction
- H01L33/06—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a quantum effect structure or superlattice, e.g. tunnel junction within the light emitting region, e.g. quantum confinement structure or tunnel barrier
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
- H01L33/20—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a particular shape, e.g. curved or truncated substrate
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/62—Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/16—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits
- H01L25/167—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits comprising optoelectronic devices, e.g. LED, photodiodes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0008—Processes
- H01L2933/0033—Processes relating to semiconductor body packages
- H01L2933/0066—Processes relating to semiconductor body packages relating to arrangements for conducting electric current to or from the semiconductor body
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0062—Processes for devices with an active region comprising only III-V compounds
- H01L33/0066—Processes for devices with an active region comprising only III-V compounds with a substrate not being a III-V compound
- H01L33/007—Processes for devices with an active region comprising only III-V compounds with a substrate not being a III-V compound comprising nitride compounds
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/005—Processes
- H01L33/0093—Wafer bonding; Removal of the growth substrate
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/02—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies
- H01L33/04—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor bodies with a quantum effect structure or superlattice, e.g. tunnel junction
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/36—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the electrodes
- H01L33/38—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the electrodes with a particular shape
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/44—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the coatings, e.g. passivation layer or anti-reflective coating
Definitions
- the present invention relates to display technology, more particularly, to a micro light emitting diode, an array substrate, a display apparatus, and a method of fabricating an array substrate.
- micro LED micro light emitting diode
- the micro LED-based display panels have the advantages of high brightness, high contrast ratio, fast response, and low power consumption.
- the micro LED-based display technology has found a wide range of applications in the display field, including smartphones and smart watches.
- the present invention provides a micro light emitting diode (micro LED), comprising a base substrate; a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate; an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate
- a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode has a substantially inverted trapezoidal shape.
- the micro LED further comprises a protection layer, wherein the protection layer is on at least one of perimeters of the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode.
- the protection layer is on each of outer peripheral sides of the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode.
- a first portion of the protection layer is on a side of the first electrode away from the quantum-well layer, and a second portion of the protection layer is on a side of the second electrode away from the quantum-well layer.
- the present invention provides an array substrate, comprising: an array of a plurality of micro light emitting diodes (micro LEDs) on a base substrate; wherein a respective one of the plurality of micro LEDs comprises a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate; an orthographic projection of the second type doped semiconductor
- the array substrate further comprises a bonding pad in contact with the first electrode and between the first electrode and the base substrate; wherein a volume of the bonding pad is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode has a substantially inverted trapezoidal shape.
- the array substrate further comprises an array of a plurality of thin film transistors on the base substrate; a pixel definition layer defining a plurality of subpixel apertures; an insulating layer on a side of the pixel definition layer away from the base substrate; and a common electrode layer on a side of the insulating layer away from the base substrate; wherein a drain electrode of a respective one of the plurality of thin film transistors is electrically connected to the first electrode of the respective one of the plurality of micro LEDs; and the common electrode layer is a unitary layer electrically connected to the second electrode of the respective one of the plurality of micro LEDs.
- the present invention provides a display apparatus, comprising the array substrate described herein or fabricated by a method described herein, and one or more integrated circuits electrically connected to the array substrate.
- the present invention provides a method of fabricating an array substrate, comprising forming a plurality of micro light emitting diodes (micro LEDs) on a base substrate; wherein forming a respective one of the plurality of micro LEDs comprises forming a first electrode on a base substrate; forming a first type doped semiconductor layer on a side of the first electrode away from the base substrate; forming a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; forming a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and forming a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor
- the method further comprises forming a first intermediate substrate by providing a growth layer; forming a second type doped semiconductor material layer on the growth layer; forming a quantum-well material layer on a side of the second type doped semiconductor material layer away from the growth layer; forming a first type doped semiconductor material layer on a side of the quantum-well material layer away from the second type doped semiconductor material layer; and forming a first electrode material layer on a side of the first type doped semiconductor material layer away from the quantum-well material layer.
- the method further comprises attaching the first intermediate substrate to a support so that the first electrode material layer is attached to a surface of the support, and the growth layer is on a side of the first electrode material layer away from the support; removing the growth layer to expose a surface of second type doped semiconductor material layer; and forming a second electrode material layer on a side of the second type doped semiconductor material layer away from the quantum-well material layer, thereby forming a second intermediate substrate.
- the method further comprises etching the second intermediate substrate to form the plurality of micro LEDs; wherein the second intermediate substrate is etched so that an orthographic projection of the first type doped semiconductor layer on the support covers, and has an area greater than, an orthographic projection of the first electrode on the support; an orthographic projection of the quantum-well layer on the support covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the support; an orthographic projection of the second type doped semiconductor layer on the support covers, and has an area greater than, the orthographic projection of the quantum-well layer on the support; and an orthographic projection of the second electrode on the support covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the support.
- the support comprises a sacrificial layer
- the first intermediate substrate is attached to the support so that the first electrode material layer is attached to a surface of the sacrificial layer, and the growth layer is on a side of the first electrode material layer away from the sacrificial layer; subsequent to etching the second intermediate substrate, the method further comprises etching the sacrificial layer to partially remove the sacrificial layer to form a reduced sacrificial layer, a portion of the sacrificial layer between adjacent micro LEDs of the plurality of micro LEDs is removed, an orthographic projection of the second electrode on the support covers, and has an area greater than, an orthographic projection of the reduced sacrificial layer on the support; and forming a protection layer covering substantially an entirety of perimeters of the first type doped semiconductor layer, the quantum-well layer, and the second type doped semiconductor layer, and at least partially covering the first electrode and the second electrode.
- the method further comprises forming a dense metal block on a side of the first electrode away from the support; wherein the dense metal block is electrically connected to the first electrode; and the dense metal block has a weight greater than at least twice of a total weight of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs; and a volume of the dense metal block is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- the method further comprises removing the plurality of micro LEDs from the support; providing a target substrate; and disposing the plurality of micro LEDs onto the target substrate.
- disposing the plurality of micro LEDs onto the target substrate comprises providing a guide plate over the target substrate, the guide plate having a plurality of openings respectively aligned with a plurality of target regions in the target substrate; and disposing the plurality of micro LEDs on the guide plate to guide the plurality of micro LEDs respectively through the plurality of openings and onto the plurality of target regions.
- the respective one of the plurality of micro LEDs is disposed onto the target substrate so that the dense metal block is in direct contact with a contact pad in a respective one of the plurality of target regions in the target substrate.
- the method further comprises heating the target substrate to convert the dense metal block into a bonding pad soldered with the contact pad; wherein the bonding pad is in direct contact with the first electrode and between the first electrode and the target substrate; and a volume of the bonding pad is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- a misplaced micro LED of the plurality of micro LEDs is disposed so that a dense metal block of the misplaced micro LED is not in direct contact with a contact pad in a corresponding one of the plurality of target regions; and subsequent to heating the target substrate, the method further comprises removing the misplaced micro LED from the target substrate.
- the present invention provides a display substrate, comprising an array substrate fabricated by the method described herein, and one or more integrated circuits connected to the array substrate.
- FIG. 1 is a cross-sectional view of a micro light emitting diode in some embodiments according to the present disclosure.
- FIG. 2 is a schematic representation of a cross-section of a micro light emitting diode in some embodiments according to the present disclosure.
- FIG. 3 is a cross-sectional view of an array substrate in some embodiments according to the present disclosure.
- FIG. 4 is a zoom-in view of a structure surrounding a respective one of a plurality of micro light emitting diodes in an array substrate in some embodiments according to the present disclosure
- FIGS. 5A to 5N illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure.
- FIGS. 6A to 6F illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure.
- each of the micro LED has to be transferred from a growth substrate to a target substrate.
- a pick-and-place transfer process is extremely time-consuming, and thus not suitable for large-scale fabrication of micro LED display panels.
- An improvement to the pick-and-place transfer is to use a printing head for transferring a plurality of micro LEDs at one time. Still, a process of transferring a large number of micro LEDs using a printing head is too complicated and time-consuming.
- misalignment between the micro LEDs and the bonding contacts in the target substrate occurs frequently in the pick-and-place transfer or the transfer process using a printing head, resulting in defects in the display panel.
- the present disclosure provides, inter alia, a micro light emitting diode, an array substrate, a display apparatus, and a method of fabricating an array substrate that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
- the present disclosure provides a micro light emitting diode (micro LED).
- the micro light emitting diode includes a base substrate; a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer.
- an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate.
- an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate.
- an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate.
- an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
- the base substrate is a base substrate of an array substrate having a plurality of thin film transistors.
- the first type doped semiconductor layer is a p-doped semiconductor layer
- the second type doped semiconductor layer is an n-doped semiconductor layer
- the first type doped semiconductor layer is an n-doped semiconductor layer
- the second type doped semiconductor layer is a p-doped semiconductor layer
- the p-doped semiconductor layer is p-doped GaN layer
- the n-doped semiconductor layer is an n-doped GaN layer.
- FIG. 1 is a cross-sectional view of a micro light emitting diode in some embodiments according to the present disclosure.
- the micro LED in some embodiments includes a base substrate 10 ; a first electrode 20 on the base substrate 10 ; a first type doped semiconductor layer 30 on a side of the first electrode 20 away from the base substrate 10 ; a quantum-well layer 40 (e.g., a multiple quantum wells layer) on a side of the first type doped semiconductor layer 30 away from the first electrode 20 ; a second type doped semiconductor layer 50 on a side of the quantum-well layer 40 away from the first type doped semiconductor layer 30 ; and a second electrode 60 on a side of the second type doped semiconductor layer 50 away from the quantum-well layer 40 .
- a quantum-well layer 40 e.g., a multiple quantum wells layer
- an orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 covers, and has an area greater than, an orthographic projection of the first electrode 20 on the base substrate 10 .
- an orthographic projection of the quantum-well layer 40 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 .
- an orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on the base substrate 10 .
- an orthographic projection of the second electrode 60 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 .
- FIG. 1 is a cross-section view along a plane intersecting with, and substantially perpendicular to, each of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 .
- the cross-section may have various appropriate shapes.
- FIG. 2 is a schematic representation of a cross-section of a micro light emitting diode in some embodiments according to the present disclosure. Referring to FIG.
- the cross-section has a first side Si closer to the base substrate 10 , a second side S 2 opposite to the first side S 1 and on a side of the first side away from the base substrate 10 , a third side S 3 connecting the first side S 1 and the second side S 2 , and a fourth side S 4 connecting the first side S 1 and the second side S 2 .
- the third side S 3 and the fourth side S 4 are lateral sides of the cross-section.
- the second side S 2 is greater than the first side S 1 .
- a first included angle ⁇ 1 formed between the first side S 1 and the third side S 3 is an obtuse angle.
- a second included angle ⁇ 2 formed between the first side S 1 and the fourth side S 4 is an obtuse angle.
- a third included angle ⁇ 3 formed between the second side S 2 and the third side S 3 is an acute angle.
- a fourth included angle ⁇ 4 formed between the second side S 2 and the fourth side S 4 is an acute angle.
- a fifth included angle ⁇ 5 formed between the third side S 3 and a surface S of the base substrate 10 is an acute angle.
- a sixth included angle ⁇ 6 formed between the fourth side S 4 and a surface S of the base substrate 10 is an acute angle. In one example, as shown in FIG.
- a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 has a substantially inverted trapezoidal shape.
- the shape of the cross-section is not limited to a substantially inverted trapezoidal shape.
- FIG. 3 is a cross-sectional view of an array substrate in some embodiments according to the present disclosure.
- FIG. 4 is a zoom-in view of a structure surrounding a respective one of a plurality of micro light emitting diodes in an array substrate in some embodiments according to the present disclosure.
- the array substrate in some embodiments includes a plurality of micro light emitting diodes 2 .
- a respective one of the plurality of micro light emitting diodes 2 in some embodiments includes a base substrate 10 ; a first electrode 20 on the base substrate 10 ; a first type doped semiconductor layer 30 on a side of the first electrode 20 away from the base substrate 10 ; a quantum-well layer 40 on a side of the first type doped semiconductor layer 30 away from the first electrode 20 ; a second type doped semiconductor layer 50 on a side of the quantum-well layer 40 away from the first type doped semiconductor layer 30 ; and a second electrode 60 on a side of the second type doped semiconductor layer 50 away from the quantum-well layer 40 .
- an orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 covers, and has an area greater than, an orthographic projection of the first electrode 20 on the base substrate 10 .
- an orthographic projection of the quantum-well layer 40 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 .
- an orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on the base substrate 10 .
- an orthographic projection of the second electrode 60 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 .
- the respective one of the plurality of micro light emitting diodes 2 further includes a bonding pad 70 in direct contact with the first electrode 20 and between the first electrode 20 and the base substrate 10 .
- a volume of the bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the bonding pad 70 is no more than a half of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the bonding pad 70 is no more than a quarter of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the bonding pad 70 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the bonding pad 70 has a weight greater than at least twice of the total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- a first thickness t 1 of the bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total thickness t 2 of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 refers to a thickness of the bonding pad 70 along a direction substantially perpendicular to each of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the total thickness t 2 is a thickness with respect to the direction substantially perpendicular to each of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 of the bonding pad 70 is no more than a half of the total thickness t 2 of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 of the bonding pad 70 is no more than a quarter of the total thickness t 2 of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- a first width w 1 of the bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a maximum width w 2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- a maximum width w 2 of the respective one of the plurality of micro LEDs 2 e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one
- the first width w 1 refers to a width of the bonding pad 70 along a direction substantially parallel to an interface between the first electrode 20 and the bonding pad 70 .
- the maximum width w 2 is a thickness with respect to the direction substantially parallel to an interface between the first electrode 20 and the bonding pad 70 .
- the first width w 1 of the bonding pad 70 is no more than a half of the maximum width w 2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- the first width w 1 of the bonding pad 70 is no more than a quarter of the maximum width w 2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- the array substrate further includes a protection layer 80 covering substantially an entirety of perimeters of the first type doped semiconductor layer 30 , the quantum-well layer 40 , and the second type doped semiconductor layer 50 , and at least partially covering the first electrode 20 and the second electrode 60 .
- the protection layer 80 covers an entirety of perimeters of the first electrode 20 and the second electrode 60 .
- the protection layer 80 further covers a portion of a bottom surface of the first electrode 20 .
- the protection layer 80 further covers a portion of a top surface of the second electrode 60 .
- the protection layer 80 is on at least one of perimeters of the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 .
- the protection layer 80 is on each of outer peripheral sides of the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 .
- a first portion of the protection layer 80 is on a side of the first electrode 20 away from the quantum-well layer 40 .
- a second portion of the protection layer 80 is on a side of the second electrode 60 away from the quantum-well layer 40 .
- the array substrate further includes an array of a plurality of thin film transistors 4 on the base substrate 10 ; a pixel definition layer 5 defining a plurality of subpixel apertures SAP; an insulating layer 6 on a side of the pixel definition layer 5 away from the base substrate 10 ; and a common electrode layer 7 on a side of the insulating layer 6 away from the base substrate 10 .
- the base substrate 10 is a base substrate of a thin film transistor back plate 3 .
- a drain electrode of a respective one of the plurality of thin film transistors 4 is electrically connected to the first electrode 20 of the respective one of the plurality of micro light emitting diodes 2 .
- the common electrode layer 7 is a unitary layer electrically connected to the second electrode 60 of the respective one of the plurality of micro light emitting diodes 2 .
- the present disclosure provides a method of fabricating an array substrate.
- the method includes forming a plurality of micro light emitting diodes (micro LEDs) on a base substrate.
- forming a respective one of the plurality of micro LEDs includes forming a first electrode on a base substrate; forming a first type doped semiconductor layer on a side of the first electrode away from the base substrate; forming a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; forming a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and forming a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer.
- an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate.
- an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate.
- an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate.
- an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
- FIGS. 5A to 5N illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure.
- the method in some embodiments includes forming a growth layer 200 on a wafer 100 .
- the growth layer 200 is a gallium nitride (GaN) substrate for epitaxial growth of micro LED layers.
- GaN gallium nitride
- the method further includes forming a second type doped semiconductor material layer 300 on the growth layer 200 ; forming a quantum-well material layer 400 on a side of the second type doped semiconductor material layer 300 away from the growth layer 200 ; forming a first type doped semiconductor material layer 500 on a side of the quantum-well material layer 400 away from the second type doped semiconductor material layer 300 ; and forming a first electrode material layer 600 on a side of the first type doped semiconductor material layer 500 away from the quantum-well material layer 400 .
- a first intermediate substrate IS 1 is formed.
- the growth layer 200 may be made of a semiconductor material such as silicon.
- the first intermediate substrate ISI is flipped and is attached to a support SR Specifically, subsequent to forming the first intermediate substrate IS 1 , the method further includes attaching the first intermediate substrate IS 1 to a support SP so that the first electrode material layer 600 is attached to a surface of the support SP, and the growth layer 200 is on a side of the first electrode material layer 600 away from the support SP.
- the method further includes attaching the first intermediate substrate IS 1 to a support SP so that the first electrode material layer 600 is attached to a surface of the support SP, and the growth layer 200 is on a side of the first electrode material layer 600 away from the support SP.
- the support SP includes a sacrificial layer 700
- the first intermediate substrate IS 1 is attached to the support SP so that the first electrode material layer 600 is attached to a surface of the sacrificial layer 700
- the growth layer 200 is on a side of the first electrode material layer 600 away from the sacrificial layer 700 .
- the method in sonic embodiments further includes removing the wafer 100 , and removing the growth layer 200 (e.g., by etching) to expose a surface of second type doped semiconductor material layer 300 .
- the method in some embodiments further includes forming a second electrode material layer 800 on a side of the second type doped semiconductor material layer 300 away from the quantum-well material layer 400 , thereby forming a second intermediate substrate IS 2 .
- the method in some embodiments further includes etching the second intermediate substrate IS 2 to form the plurality of Micro light emitting diodes 2 .
- etching methods include, but are not limited to, reactive ion etching (RIE), deep reactive ion etching (DRIE), inductively coupled plasma etching (ICP), electron cyclotron resonance etching (ECR), ion beam etching, and laser machining.
- etching gas may be used for dry etching. Examples of plasma etching gas include, but are not limited to, boron chloride (BCl 3 ) and chlorine (Cl 2 ).
- the step of etching the second intermediate substrate IS 2 is performed using an inductively coupled plasma etching process.
- plasma etching gas for performing the inductively coupled plasma etching process includes boron chloride (BCl 3 ), carbon fluoride (CF 4 ), and chlorine (Cl 2 ).
- the second intermediate substrate IS 2 is etched so that an orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 covers, and has an area greater than, an orthographic projection of the first electrode 20 on the base substrate 10 .
- the second intermediate substrate IS 2 is etched so that an orthographic projection of the quantum-well layer 40 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer 30 on the base substrate 10 .
- the second intermediate substrate IS 2 is etched so that an orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on the base substrate 10 .
- the second intermediate substrate IS 2 is etched so that an orthographic projection of the second electrode 60 on the base substrate 10 covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer 50 on the base substrate 10 .
- the method further includes etching the sacrificial layer 700 to partially remove the sacrificial layer 700 to form a reduced sacrificial layer 900 .
- etching the sacrificial layer 700 to partially remove the sacrificial layer 700 to form a reduced sacrificial layer 900 .
- a portion of the sacrificial layer 700 between adjacent micro light emitting diodes of the plurality of micro light emitting diodes 2 is removed.
- an orthographic projection of the second electrode 60 on the support SP covers, and has an area greater than, an orthographic projection of the reduced sacrificial layer 900 on the support SP. Etching the sacrificial layer 700 into the reduced sacrificial layer 900 makes it easier to remove the plurality of micro light emitting diodes 2 from the support SP in a subsequent process.
- the method further includes forming a protection layer 80 to cover substantially an entirety of perimeters of the first type doped semiconductor layer 30 , the quantum-well layer 40 , and the second type doped semiconductor layer 50 , and at least partially covering the first electrode 20 and the second electrode 60 .
- the protection layer 80 is formed to cover an entirety of perimeters of the first electrode 20 and the second electrode 60 .
- the protection layer 80 is formed to further cover a portion of a bottom surface of the first electrode 20 .
- the protection layer 80 is formed to further cover a portion of a top surface of the second electrode 60 .
- the protection layer 80 is formed on at least one of perimeters of the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 .
- the protection layer 80 is formed on each of outer peripheral sides of the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 .
- a first portion of the protection layer 80 is formed on a side of the first electrode 20 away from the quantum-well layer 40 .
- a second portion of the protection layer 80 is formed on a side of the second electrode 60 away from the quantum-well layer 40 .
- the method further includes forming a dense metal block 90 on a side of the first electrode 20 away from the support SP.
- the dense metal block 90 is formed to be electrically connected to the first electrode 20 .
- the dense metal block 90 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the dense metal block 90 has a weight greater than at least twice of the total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- a volume of the dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the dense metal block 90 is no more than a half of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the dense metal block 90 is no more than a quarter of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- a first thickness t 1 ′ of the dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total thickness t 2 ′ of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 ′ refers to a thickness of the dense metal block 90 along a direction substantially perpendicular to each of the first electrode the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the total thickness t 2 ′ is a thickness with respect to the direction substantially perpendicular to each of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 ′ of the dense metal block 90 is no more than a half of the total thickness t 2 ′ of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the first thickness t 1 ′ of the dense metal block 90 is no more than a quarter of the total thickness t 2 of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- a first width w 1 ′ of the dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a maximum width the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- a maximum width the respective one of the plurality of micro LEDs 2 e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro
- the first width w 1 refers to a width of the dense metal block 90 along a direction substantially parallel to an interface between the first electrode 20 and the dense metal block 90 .
- the maximum width w 2 ′ is a thickness with respect to the direction substantially parallel to an interface between the first electrode 20 and the dense metal block 90 .
- the first width w 1 ′ of the dense metal block 90 is no more than a half of the maximum width w 2 ′ of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- the first width w 1 ′ of the dense metal block 90 is no more than a quarter of the maximum width w 2 ′ of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 ).
- the method further includes removing the plurality of micro LEDs 2 from the support SP, e.g., by etching the reduced sacrificial layer 900 , or by using a lift-off method.
- the method in some embodiments further includes providing a target substrate TS; and disposing the plurality of micro LEDs 2 onto the target substrate Th.
- the method in some embodiments includes providing a guide plate GP (e.g., a shaking sieve) over the target substrate TS, the guide plate GP having a plurality of openings OP respectively aligned with a plurality of target regions TR in the target substrate TS.
- the plurality of target regions TR are defined by a pixel definition layer 5 .
- the method in some embodiments further includes disposing the plurality of micro LEDs 2 on the guide plate GP to guide the plurality of micro LEDs 2 respectively through the plurality of openings OP and onto the plurality of target regions TR.
- the respective one of the plurality of micro LEDs 2 is disposed onto the target substrate TS so that the dense metal block 90 is in direct contact with a contact pad CP in a respective one of the plurality of target regions TR in the target substrate TS.
- the method in some embodiments further includes heating the target substrate TS to convert the dense metal block 90 into a bonding pad 70 soldered with the contact pad CP.
- the bonding pad 70 is in direct contact with the first electrode 20 and is between the first electrode 20 and the target substrate TS.
- a volume of the bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the bonding pad 70 is no more than a half of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the volume of the bonding pad 70 is no more than a quarter of the total volume of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the bonding pad 70 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- the bonding pad 70 has a weight greater than at least twice of the total weight of the first electrode 20 , the first type doped semiconductor layer 30 , the quantum-well layer 40 , the second type doped semiconductor layer 50 , and the second electrode 60 in the respective one of the plurality of micro LEDs 2 .
- An array substrate is then formed.
- the method in some embodiments further includes forming an insulating layer 6 on the plurality of micro LEDs 2 ; and a common electrode layer 7 on a side of the insulating layer 6 away from the plurality of micro LEDs 2 .
- the target substrate TS is a thin film transistor array substrate.
- the common electrode layer 7 is a unitary layer electrically connected to the respective one of the plurality of micro light emitting diodes 2 .
- FIGS. 6A to 6F illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure.
- some micro LEDs may be misplaced so that the dense metal block cannot be soldered with a contact pad.
- a misplaced micro LED 2 ′ of the plurality of micro LEDs is disposed so that a dense metal block 90 of the misplaced micro LED 2 ′ is not in direct contact with a contact pad CP in a corresponding one of the plurality of target regions TR.
- the target substrate TS is heated to convert the dense metal block 90 of the micro LEDs that are not misplaced into a bonding pad 70 , and the bonding pad 70 is soldered with the contact pad CP.
- the bonding pad 70 is in direct contact with the first electrode 20 and is between the first electrode 20 and the target substrate TS.
- the dense metal block 90 of the misplaced micro LED 2 ′ is not in direct contact with the contact pad CP, and is not converted into the bonding pad 70 .
- the method further includes removing the misplaced micro LED 2 ′ from the target substrate TS.
- the target substrate TS is flipped upside down. Because the misplaced micro LED 2 ′ is not soldered with the contact pad, it falls off the target substrate TS.
- a replacement micro LED 2 ′′ with a dense metal block 90 may be transferred, e.g., individually transferred, onto the target substrate TS.
- the target substrate TS is heated again to convert the dense metal block 90 of the replacement micro LEDs 2 ′′ into a bonding pad 70 , and the bonding pad 70 is soldered with the contact pad CP.
- the bonding pad 70 is in direct contact with the first electrode 20 of the replacement micro LEDs 2 ′′ and is between the first electrode 20 and the target substrate TS.
- the method in some embodiments further includes forming an insulating layer 6 on the plurality of micro LEDs 2 ; and a common electrode layer 7 on a side of the insulating layer 6 away from the plurality of micro LEDs 2 .
- the target substrate TS is a thin film transistor array substrate.
- the common electrode layer 7 is a unitary layer electrically connected to the respective one of the plurality of micro light emitting diodes 2 .
- the present disclosure provides a display apparatus having the array substrate described herein or fabricated by a method described herein, or having the micro light emitting diode described herein or fabricated by a method described herein.
- the display apparatus further includes one or more integrated circuits connected to the array substrate. Examples of appropriate display apparatuses include, but are not limited to, an electronic paper, a mobile phone, a tablet computer, a television, a monitor, a notebook computer, a digital album, a GPS, etc.
- the term “the invention”, “the present invention” or the like does not necessarily limit the claim scope to a specific embodiment, and the reference to exemplary embodiments of the invention does not imply a limitation on the invention, and no such limitation is to be inferred.
- the invention is limited only by the spirit and scope of the appended claims. Moreover, these claims may refer to use “first”, “second”, etc, following with noun or element. Such terms should be understood as a nomenclature and should not be construed as giving the limitation on the number of the elements modified by such nomenclature unless specific number has been given. Any advantages and benefits described may not apply to all embodiments of the invention.
Landscapes
- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Computer Hardware Design (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- General Physics & Mathematics (AREA)
- Led Devices (AREA)
Abstract
Description
- The present invention relates to display technology, more particularly, to a micro light emitting diode, an array substrate, a display apparatus, and a method of fabricating an array substrate.
- In recent years, miniaturized electro-optics devices are proposed and developed, including micro light emitting diode (micro LED). The micro LED-based display panels have the advantages of high brightness, high contrast ratio, fast response, and low power consumption. The micro LED-based display technology has found a wide range of applications in the display field, including smartphones and smart watches.
- In one aspect, the present invention provides a micro light emitting diode (micro LED), comprising a base substrate; a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate; an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate; and an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
- Optionally, a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode, has a substantially inverted trapezoidal shape.
- Optionally, the micro LED further comprises a protection layer, wherein the protection layer is on at least one of perimeters of the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode.
- Optionally, the protection layer is on each of outer peripheral sides of the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode.
- Optionally, a first portion of the protection layer is on a side of the first electrode away from the quantum-well layer, and a second portion of the protection layer is on a side of the second electrode away from the quantum-well layer.
- In another aspect, the present invention provides an array substrate, comprising: an array of a plurality of micro light emitting diodes (micro LEDs) on a base substrate; wherein a respective one of the plurality of micro LEDs comprises a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate; an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate; and an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
- Optionally, the array substrate further comprises a bonding pad in contact with the first electrode and between the first electrode and the base substrate; wherein a volume of the bonding pad is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- Optionally, in the respective one of the plurality of micro LEDs, a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode, has a substantially inverted trapezoidal shape.
- Optionally, the array substrate further comprises an array of a plurality of thin film transistors on the base substrate; a pixel definition layer defining a plurality of subpixel apertures; an insulating layer on a side of the pixel definition layer away from the base substrate; and a common electrode layer on a side of the insulating layer away from the base substrate; wherein a drain electrode of a respective one of the plurality of thin film transistors is electrically connected to the first electrode of the respective one of the plurality of micro LEDs; and the common electrode layer is a unitary layer electrically connected to the second electrode of the respective one of the plurality of micro LEDs.
- In another aspect, the present invention provides a display apparatus, comprising the array substrate described herein or fabricated by a method described herein, and one or more integrated circuits electrically connected to the array substrate.
- In another aspect, the present invention provides a method of fabricating an array substrate, comprising forming a plurality of micro light emitting diodes (micro LEDs) on a base substrate; wherein forming a respective one of the plurality of micro LEDs comprises forming a first electrode on a base substrate; forming a first type doped semiconductor layer on a side of the first electrode away from the base substrate; forming a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; forming a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and forming a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer; wherein an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate; an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate; an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate; and an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
- Optionally, prior to forming the plurality of micro LEDs, the method further comprises forming a first intermediate substrate by providing a growth layer; forming a second type doped semiconductor material layer on the growth layer; forming a quantum-well material layer on a side of the second type doped semiconductor material layer away from the growth layer; forming a first type doped semiconductor material layer on a side of the quantum-well material layer away from the second type doped semiconductor material layer; and forming a first electrode material layer on a side of the first type doped semiconductor material layer away from the quantum-well material layer.
- Optionally, subsequent to forming the first intermediate substrate, the method further comprises attaching the first intermediate substrate to a support so that the first electrode material layer is attached to a surface of the support, and the growth layer is on a side of the first electrode material layer away from the support; removing the growth layer to expose a surface of second type doped semiconductor material layer; and forming a second electrode material layer on a side of the second type doped semiconductor material layer away from the quantum-well material layer, thereby forming a second intermediate substrate.
- Optionally, the method further comprises etching the second intermediate substrate to form the plurality of micro LEDs; wherein the second intermediate substrate is etched so that an orthographic projection of the first type doped semiconductor layer on the support covers, and has an area greater than, an orthographic projection of the first electrode on the support; an orthographic projection of the quantum-well layer on the support covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the support; an orthographic projection of the second type doped semiconductor layer on the support covers, and has an area greater than, the orthographic projection of the quantum-well layer on the support; and an orthographic projection of the second electrode on the support covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the support.
- Optionally, the support comprises a sacrificial layer, the first intermediate substrate is attached to the support so that the first electrode material layer is attached to a surface of the sacrificial layer, and the growth layer is on a side of the first electrode material layer away from the sacrificial layer; subsequent to etching the second intermediate substrate, the method further comprises etching the sacrificial layer to partially remove the sacrificial layer to form a reduced sacrificial layer, a portion of the sacrificial layer between adjacent micro LEDs of the plurality of micro LEDs is removed, an orthographic projection of the second electrode on the support covers, and has an area greater than, an orthographic projection of the reduced sacrificial layer on the support; and forming a protection layer covering substantially an entirety of perimeters of the first type doped semiconductor layer, the quantum-well layer, and the second type doped semiconductor layer, and at least partially covering the first electrode and the second electrode.
- Optionally, the method further comprises forming a dense metal block on a side of the first electrode away from the support; wherein the dense metal block is electrically connected to the first electrode; and the dense metal block has a weight greater than at least twice of a total weight of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs; and a volume of the dense metal block is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- Optionally, subsequent to forming the dense metal block, the method further comprises removing the plurality of micro LEDs from the support; providing a target substrate; and disposing the plurality of micro LEDs onto the target substrate.
- Optionally, disposing the plurality of micro LEDs onto the target substrate comprises providing a guide plate over the target substrate, the guide plate having a plurality of openings respectively aligned with a plurality of target regions in the target substrate; and disposing the plurality of micro LEDs on the guide plate to guide the plurality of micro LEDs respectively through the plurality of openings and onto the plurality of target regions.
- Optionally, the respective one of the plurality of micro LEDs is disposed onto the target substrate so that the dense metal block is in direct contact with a contact pad in a respective one of the plurality of target regions in the target substrate.
- Optionally, the method further comprises heating the target substrate to convert the dense metal block into a bonding pad soldered with the contact pad; wherein the bonding pad is in direct contact with the first electrode and between the first electrode and the target substrate; and a volume of the bonding pad is no more than a half of a total volume of the first electrode, the first type doped semiconductor layer, the quantum-well layer, the second type doped semiconductor layer, and the second electrode in the respective one of the plurality of micro LEDs.
- Optionally, a misplaced micro LED of the plurality of micro LEDs is disposed so that a dense metal block of the misplaced micro LED is not in direct contact with a contact pad in a corresponding one of the plurality of target regions; and subsequent to heating the target substrate, the method further comprises removing the misplaced micro LED from the target substrate.
- In another aspect, the present invention provides a display substrate, comprising an array substrate fabricated by the method described herein, and one or more integrated circuits connected to the array substrate.
- The following drawings are merely examples for illustrative purposes according to various disclosed embodiments and are not intended to limit the scope of the present invention.
-
FIG. 1 is a cross-sectional view of a micro light emitting diode in some embodiments according to the present disclosure. -
FIG. 2 is a schematic representation of a cross-section of a micro light emitting diode in some embodiments according to the present disclosure. -
FIG. 3 is a cross-sectional view of an array substrate in some embodiments according to the present disclosure. -
FIG. 4 is a zoom-in view of a structure surrounding a respective one of a plurality of micro light emitting diodes in an array substrate in some embodiments according to the present disclosure, -
FIGS. 5A to 5N illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure. -
FIGS. 6A to 6F illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure. - The disclosure will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of some embodiments are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.
- In fabricating a micro light emitting diode (micro LED) display panel, each of the micro LED has to be transferred from a growth substrate to a target substrate. Considering the display panel includes thousands to millions of micro LEDs, a pick-and-place transfer process is extremely time-consuming, and thus not suitable for large-scale fabrication of micro LED display panels. An improvement to the pick-and-place transfer is to use a printing head for transferring a plurality of micro LEDs at one time. Still, a process of transferring a large number of micro LEDs using a printing head is too complicated and time-consuming. Moreover, misalignment between the micro LEDs and the bonding contacts in the target substrate occurs frequently in the pick-and-place transfer or the transfer process using a printing head, resulting in defects in the display panel.
- Accordingly, the present disclosure provides, inter alia, a micro light emitting diode, an array substrate, a display apparatus, and a method of fabricating an array substrate that substantially obviate one or more of the problems due to limitations and disadvantages of the related art. In one aspect, the present disclosure provides a micro light emitting diode (micro LED). In some embodiments, the micro light emitting diode includes a base substrate; a first electrode on the base substrate; a first type doped semiconductor layer on a side of the first electrode away from the base substrate; a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer. Optionally, an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate. Optionally, an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate. Optionally, an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate. Optionally, an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate. Optionally, the base substrate is a base substrate of an array substrate having a plurality of thin film transistors. Optionally, the first type doped semiconductor layer is a p-doped semiconductor layer, and the second type doped semiconductor layer is an n-doped semiconductor layer. Optionally, the first type doped semiconductor layer is an n-doped semiconductor layer, and the second type doped semiconductor layer is a p-doped semiconductor layer. Optionally, the p-doped semiconductor layer is p-doped GaN layer, and the n-doped semiconductor layer is an n-doped GaN layer.
-
FIG. 1 is a cross-sectional view of a micro light emitting diode in some embodiments according to the present disclosure. Referring toFIG. 1 , the micro LED in some embodiments includes abase substrate 10; afirst electrode 20 on thebase substrate 10; a first type dopedsemiconductor layer 30 on a side of thefirst electrode 20 away from thebase substrate 10; a quantum-well layer 40 (e.g., a multiple quantum wells layer) on a side of the first type dopedsemiconductor layer 30 away from thefirst electrode 20; a second type dopedsemiconductor layer 50 on a side of the quantum-well layer 40 away from the first type dopedsemiconductor layer 30; and asecond electrode 60 on a side of the second type dopedsemiconductor layer 50 away from the quantum-well layer 40. Optionally, an orthographic projection of the first type dopedsemiconductor layer 30 on thebase substrate 10 covers, and has an area greater than, an orthographic projection of thefirst electrode 20 on thebase substrate 10. Optionally, an orthographic projection of the quantum-well layer 40 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the first type dopedsemiconductor layer 30 on thebase substrate 10. Optionally, an orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on thebase substrate 10. Optionally, an orthographic projection of thesecond electrode 60 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10. -
FIG. 1 is a cross-section view along a plane intersecting with, and substantially perpendicular to, each of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60. The cross-section may have various appropriate shapes.FIG. 2 is a schematic representation of a cross-section of a micro light emitting diode in some embodiments according to the present disclosure. Referring toFIG. 2 , the cross-section has a first side Si closer to thebase substrate 10, a second side S2 opposite to the first side S1 and on a side of the first side away from thebase substrate 10, a third side S3 connecting the first side S1 and the second side S2, and a fourth side S4 connecting the first side S1 and the second side S2. The third side S3 and the fourth side S4 are lateral sides of the cross-section. The second side S2 is greater than the first side S1. Optionally, a first included angle α1 formed between the first side S1 and the third side S3 is an obtuse angle. Optionally, a second included angle α2 formed between the first side S1 and the fourth side S4 is an obtuse angle. Optionally, a third included angle α3 formed between the second side S2 and the third side S3 is an acute angle. Optionally, a fourth included angle α4 formed between the second side S2 and the fourth side S4 is an acute angle. Optionally, a fifth included angle α5 formed between the third side S3 and a surface S of thebase substrate 10 is an acute angle. Optionally, a sixth included angle α6 formed between the fourth side S4 and a surface S of thebase substrate 10 is an acute angle. In one example, as shown inFIG. 1 , a cross-section of the micro LED along a plane intersecting with, and substantially perpendicular to, each of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60, has a substantially inverted trapezoidal shape. The shape of the cross-section, however, is not limited to a substantially inverted trapezoidal shape. -
FIG. 3 is a cross-sectional view of an array substrate in some embodiments according to the present disclosure.FIG. 4 is a zoom-in view of a structure surrounding a respective one of a plurality of micro light emitting diodes in an array substrate in some embodiments according to the present disclosure. Referring toFIG. 3 , the array substrate in some embodiments includes a plurality of micro light emitting diodes 2. Referring toFIG. 1 andFIG. 2 , a respective one of the plurality of micro light emitting diodes 2 in some embodiments includes abase substrate 10; afirst electrode 20 on thebase substrate 10; a first type dopedsemiconductor layer 30 on a side of thefirst electrode 20 away from thebase substrate 10; a quantum-well layer 40 on a side of the first type dopedsemiconductor layer 30 away from thefirst electrode 20; a second type dopedsemiconductor layer 50 on a side of the quantum-well layer 40 away from the first type dopedsemiconductor layer 30; and asecond electrode 60 on a side of the second type dopedsemiconductor layer 50 away from the quantum-well layer 40. Optionally, an orthographic projection of the first type dopedsemiconductor layer 30 on thebase substrate 10 covers, and has an area greater than, an orthographic projection of thefirst electrode 20 on thebase substrate 10. Optionally, an orthographic projection of the quantum-well layer 40 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the first type dopedsemiconductor layer 30 on thebase substrate 10. Optionally, an orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on thebase substrate 10. Optionally, an orthographic projection of thesecond electrode 60 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10. - Referring to
FIG. 3 andFIG. 4 , in some embodiments, the respective one of the plurality of micro light emitting diodes 2 further includes abonding pad 70 in direct contact with thefirst electrode 20 and between thefirst electrode 20 and thebase substrate 10. Optionally, a volume of thebonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thebonding pad 70 is no more than a half of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thebonding pad 70 is no more than a quarter of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, the
bonding pad 70 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, thebonding pad 70 has a weight greater than at least twice of the total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, a first thickness t1 of the
bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total thickness t2 of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. The first thickness t1 refers to a thickness of thebonding pad 70 along a direction substantially perpendicular to each of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Similarly, the total thickness t2 is a thickness with respect to the direction substantially perpendicular to each of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the first thickness t1 of thebonding pad 70 is no more than a half of the total thickness t2 of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the first thickness t1 of thebonding pad 70 is no more than a quarter of the total thickness t2 of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, a first width w1 of the
bonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a maximum width w2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). The first width w1 refers to a width of thebonding pad 70 along a direction substantially parallel to an interface between thefirst electrode 20 and thebonding pad 70. Similarly, the maximum width w2 is a thickness with respect to the direction substantially parallel to an interface between thefirst electrode 20 and thebonding pad 70. Optionally, the first width w1 of thebonding pad 70 is no more than a half of the maximum width w2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). Optionally, the first width w1 of thebonding pad 70 is no more than a quarter of the maximum width w2 of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). - Referring to
FIG. 3 andFIG. 4 again, in some embodiments, the array substrate further includes aprotection layer 80 covering substantially an entirety of perimeters of the first type dopedsemiconductor layer 30, the quantum-well layer 40, and the second type dopedsemiconductor layer 50, and at least partially covering thefirst electrode 20 and thesecond electrode 60. Optionally, theprotection layer 80 covers an entirety of perimeters of thefirst electrode 20 and thesecond electrode 60. Optionally, theprotection layer 80 further covers a portion of a bottom surface of thefirst electrode 20. Optionally, theprotection layer 80 further covers a portion of a top surface of thesecond electrode 60. Optionally, theprotection layer 80 is on at least one of perimeters of the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60. Optionally, theprotection layer 80 is on each of outer peripheral sides of the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60. Optionally, a first portion of theprotection layer 80 is on a side of thefirst electrode 20 away from the quantum-well layer 40. Optionally, a second portion of theprotection layer 80 is on a side of thesecond electrode 60 away from the quantum-well layer 40. - In some embodiments, the array substrate further includes an array of a plurality of
thin film transistors 4 on thebase substrate 10; apixel definition layer 5 defining a plurality of subpixel apertures SAP; an insulatinglayer 6 on a side of thepixel definition layer 5 away from thebase substrate 10; and acommon electrode layer 7 on a side of the insulatinglayer 6 away from thebase substrate 10. In one example, thebase substrate 10 is a base substrate of a thin film transistor backplate 3. A drain electrode of a respective one of the plurality ofthin film transistors 4 is electrically connected to thefirst electrode 20 of the respective one of the plurality of micro light emitting diodes 2. Optionally, as shown inFIG. 3 , thecommon electrode layer 7 is a unitary layer electrically connected to thesecond electrode 60 of the respective one of the plurality of micro light emitting diodes 2. - In another aspect, the present disclosure provides a method of fabricating an array substrate. In some embodiments, the method includes forming a plurality of micro light emitting diodes (micro LEDs) on a base substrate. In some embodiments, forming a respective one of the plurality of micro LEDs includes forming a first electrode on a base substrate; forming a first type doped semiconductor layer on a side of the first electrode away from the base substrate; forming a quantum-well layer on a side of the first type doped semiconductor layer away from the first electrode; forming a second type doped semiconductor layer on a side of the quantum-well layer away from the first type doped semiconductor layer; and forming a second electrode on a side of the second type doped semiconductor layer away from the quantum-well layer. Optionally, an orthographic projection of the first type doped semiconductor layer on the base substrate covers, and has an area greater than, an orthographic projection of the first electrode on the base substrate. Optionally, an orthographic projection of the quantum-well layer on the base substrate covers, and has an area greater than, the orthographic projection of the first type doped semiconductor layer on the base substrate. Optionally, an orthographic projection of the second type doped semiconductor layer on the base substrate covers, and has an area greater than, the orthographic projection of the quantum-well layer on the base substrate. Optionally, an orthographic projection of the second electrode on the base substrate covers, and has an area greater than, the orthographic projection of the second type doped semiconductor layer on the base substrate.
-
FIGS. 5A to 5N illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure. Referring toFIG. 5A , the method in some embodiments includes forming agrowth layer 200 on awafer 100. Optionally, thegrowth layer 200 is a gallium nitride (GaN) substrate for epitaxial growth of micro LED layers. Referring toFIG. 5B , the method further includes forming a second type dopedsemiconductor material layer 300 on thegrowth layer 200; forming a quantum-well material layer 400 on a side of the second type dopedsemiconductor material layer 300 away from thegrowth layer 200; forming a first type dopedsemiconductor material layer 500 on a side of the quantum-well material layer 400 away from the second type dopedsemiconductor material layer 300; and forming a firstelectrode material layer 600 on a side of the first type dopedsemiconductor material layer 500 away from the quantum-well material layer 400. A first intermediate substrate IS1 is formed. - Various appropriate materials may be used for making the
growth layer 200. Examples of appropriate growth layer materials include silicon, sapphire, quartz, GaN, SiC, and alumina. In one example, thegrowth layer 200 is made of a semiconductor material such as silicon. - Referring to
FIG. 5C , in some embodiments, the first intermediate substrate ISI is flipped and is attached to a support SR Specifically, subsequent to forming the first intermediate substrate IS1, the method further includes attaching the first intermediate substrate IS1 to a support SP so that the firstelectrode material layer 600 is attached to a surface of the support SP, and thegrowth layer 200 is on a side of the firstelectrode material layer 600 away from the support SP. Optionally, as shown inFIG. 5C , the support SP includes asacrificial layer 700, the first intermediate substrate IS1 is attached to the support SP so that the firstelectrode material layer 600 is attached to a surface of thesacrificial layer 700, and thegrowth layer 200 is on a side of the firstelectrode material layer 600 away from thesacrificial layer 700. - Referring to
FIG. 5D , the method in sonic embodiments further includes removing thewafer 100, and removing the growth layer 200 (e.g., by etching) to expose a surface of second type dopedsemiconductor material layer 300. - Referring to
FIG. 5E , the method in some embodiments further includes forming a secondelectrode material layer 800 on a side of the second type dopedsemiconductor material layer 300 away from the quantum-well material layer 400, thereby forming a second intermediate substrate IS2. - Referring to
FIG. 5E andFIG. 5F , the method in some embodiments further includes etching the second intermediate substrate IS2 to form the plurality of Micro light emitting diodes 2. Various appropriate etching methods may be used for etching the second intermediate substrate IS2. Examples of etching methods include, but are not limited to, reactive ion etching (RIE), deep reactive ion etching (DRIE), inductively coupled plasma etching (ICP), electron cyclotron resonance etching (ECR), ion beam etching, and laser machining. Various etching gas may be used for dry etching. Examples of plasma etching gas include, but are not limited to, boron chloride (BCl3) and chlorine (Cl2). In some embodiments, the step of etching the second intermediate substrate IS2 is performed using an inductively coupled plasma etching process. Examples of plasma etching gas for performing the inductively coupled plasma etching process includes boron chloride (BCl3), carbon fluoride (CF4), and chlorine (Cl2). - Optionally, the second intermediate substrate IS2 is etched so that an orthographic projection of the first type doped
semiconductor layer 30 on thebase substrate 10 covers, and has an area greater than, an orthographic projection of thefirst electrode 20 on thebase substrate 10. Optionally, the second intermediate substrate IS2 is etched so that an orthographic projection of the quantum-well layer 40 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the first type dopedsemiconductor layer 30 on thebase substrate 10. Optionally, the second intermediate substrate IS2 is etched so that an orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the quantum-well layer 40 on thebase substrate 10. Optionally, the second intermediate substrate IS2 is etched so that an orthographic projection of thesecond electrode 60 on thebase substrate 10 covers, and has an area greater than, the orthographic projection of the second type dopedsemiconductor layer 50 on thebase substrate 10. - Referring to
FIG. 5F andFIG. 5G , in some embodiments, subsequent to etching the second intermediate substrate IS2, the method further includes etching thesacrificial layer 700 to partially remove thesacrificial layer 700 to form a reducedsacrificial layer 900. As shown inFIG. 5F andFIG. 5G , a portion of thesacrificial layer 700 between adjacent micro light emitting diodes of the plurality of micro light emitting diodes 2 is removed. Optionally, an orthographic projection of thesecond electrode 60 on the support SP covers, and has an area greater than, an orthographic projection of the reducedsacrificial layer 900 on the support SP. Etching thesacrificial layer 700 into the reducedsacrificial layer 900 makes it easier to remove the plurality of micro light emitting diodes 2 from the support SP in a subsequent process. - Referring to
FIG. 5H , in some embodiments, the method further includes forming aprotection layer 80 to cover substantially an entirety of perimeters of the first type dopedsemiconductor layer 30, the quantum-well layer 40, and the second type dopedsemiconductor layer 50, and at least partially covering thefirst electrode 20 and thesecond electrode 60. Optionally, theprotection layer 80 is formed to cover an entirety of perimeters of thefirst electrode 20 and thesecond electrode 60. Optionally, theprotection layer 80 is formed to further cover a portion of a bottom surface of thefirst electrode 20. Optionally, theprotection layer 80 is formed to further cover a portion of a top surface of thesecond electrode 60. Optionally, theprotection layer 80 is formed on at least one of perimeters of the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60. Optionally, theprotection layer 80 is formed on each of outer peripheral sides of the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60. Optionally, a first portion of theprotection layer 80 is formed on a side of thefirst electrode 20 away from the quantum-well layer 40. Optionally, a second portion of theprotection layer 80 is formed on a side of thesecond electrode 60 away from the quantum-well layer 40. - Referring to
FIG. 5I , in some embodiments, the method further includes forming adense metal block 90 on a side of thefirst electrode 20 away from the support SP. Thedense metal block 90 is formed to be electrically connected to thefirst electrode 20. Optionally, thedense metal block 90 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, the
dense metal block 90 has a weight greater than at least twice of the total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, a volume of the
dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thedense metal block 90 is no more than a half of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thedense metal block 90 is no more than a quarter of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, a first thickness t1′ of the
dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total thickness t2′ of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. The first thickness t1′ refers to a thickness of thedense metal block 90 along a direction substantially perpendicular to each of the first electrode the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Similarly, the total thickness t2′ is a thickness with respect to the direction substantially perpendicular to each of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the first thickness t1′ of thedense metal block 90 is no more than a half of the total thickness t2′ of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the first thickness t1′ of thedense metal block 90 is no more than a quarter of the total thickness t2 of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, a first width w1′ of the
dense metal block 90 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a maximum width the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). The first width w1 refers to a width of thedense metal block 90 along a direction substantially parallel to an interface between thefirst electrode 20 and thedense metal block 90. Similarly, the maximum width w2′ is a thickness with respect to the direction substantially parallel to an interface between thefirst electrode 20 and thedense metal block 90. Optionally, the first width w1′ of thedense metal block 90 is no more than a half of the maximum width w2′ of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). Optionally, the first width w1′ of thedense metal block 90 is no more than a quarter of the maximum width w2′ of the respective one of the plurality of micro LEDs 2 (e.g., a maximum width among thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2). - Referring to
FIG. 5I andFIG. 5J , in some embodiments, the method further includes removing the plurality of micro LEDs 2 from the support SP, e.g., by etching the reducedsacrificial layer 900, or by using a lift-off method. - Referring to
FIG. 5K andFIG. 5L , the method in some embodiments further includes providing a target substrate TS; and disposing the plurality of micro LEDs 2 onto the target substrate Th. Referring toFIG. 5K , the method in some embodiments includes providing a guide plate GP (e.g., a shaking sieve) over the target substrate TS, the guide plate GP having a plurality of openings OP respectively aligned with a plurality of target regions TR in the target substrate TS. Optionally, the plurality of target regions TR are defined by apixel definition layer 5. - Referring to
FIG. 5K andFIG. 5I , the method in some embodiments further includes disposing the plurality of micro LEDs 2 on the guide plate GP to guide the plurality of micro LEDs 2 respectively through the plurality of openings OP and onto the plurality of target regions TR. The respective one of the plurality of micro LEDs 2 is disposed onto the target substrate TS so that thedense metal block 90 is in direct contact with a contact pad CP in a respective one of the plurality of target regions TR in the target substrate TS. - Referring to
FIG. 5L andFIG. 5M , the method in some embodiments further includes heating the target substrate TS to convert thedense metal block 90 into abonding pad 70 soldered with the contact pad CP. Thebonding pad 70 is in direct contact with thefirst electrode 20 and is between thefirst electrode 20 and the target substrate TS. Optionally, a volume of thebonding pad 70 is no more than (e.g., no more than 90% of, no more than 80% of, no more than 70% of, no more than 60% of, no more than 50% of, no more than 40% of, no more than 30% of, no more than 20% of, no more than 10% of, no more than 5% of, or no more than 1% of) a total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thebonding pad 70 is no more than a half of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, the volume of thebonding pad 70 is no more than a quarter of the total volume of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. - Optionally, the
bonding pad 70 has a weight greater than (e.g., more than 1.1 times of, more than 2 times of, more than 3 times of, more than 4 times of, more than 5 times of, more than 6 times of, more than 7 times of, more than 8 times of, more than 9 times of, more than 10 times of, or more than 20 times of) a total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. Optionally, thebonding pad 70 has a weight greater than at least twice of the total weight of thefirst electrode 20, the first type dopedsemiconductor layer 30, the quantum-well layer 40, the second type dopedsemiconductor layer 50, and thesecond electrode 60 in the respective one of the plurality of micro LEDs 2. An array substrate is then formed. - Referring to
FIG. 5N , the method in some embodiments further includes forming an insulatinglayer 6 on the plurality of micro LEDs 2; and acommon electrode layer 7 on a side of the insulatinglayer 6 away from the plurality of micro LEDs 2. In one example, the target substrate TS is a thin film transistor array substrate. Optionally, as shown inFIG. 5N , thecommon electrode layer 7 is a unitary layer electrically connected to the respective one of the plurality of micro light emitting diodes 2. -
FIGS. 6A to 6F illustrate a method of fabricating an array substrate in some embodiments according to the present disclosure. Referring toFIG. 6A , in some embodiments, in the process of disposing the plurality of micro LEDs 2 onto the target substrate TS, some micro LEDs may be misplaced so that the dense metal block cannot be soldered with a contact pad. Optionally, as shown inFIG. 6A , a misplaced micro LED 2′ of the plurality of micro LEDs is disposed so that adense metal block 90 of the misplaced micro LED 2′ is not in direct contact with a contact pad CP in a corresponding one of the plurality of target regions TR. - Referring to 6B, the target substrate TS is heated to convert the
dense metal block 90 of the micro LEDs that are not misplaced into abonding pad 70, and thebonding pad 70 is soldered with the contact pad CP. Thebonding pad 70 is in direct contact with thefirst electrode 20 and is between thefirst electrode 20 and the target substrate TS. For the misplaced micro LED 2′, thedense metal block 90 of the misplaced micro LED 2′ is not in direct contact with the contact pad CP, and is not converted into thebonding pad 70. - In some embodiments, subsequent to heating the target substrate TS, the method further includes removing the misplaced micro LED 2′ from the target substrate TS. Referring to
FIG. 6C , in one example, the target substrate TS is flipped upside down. Because the misplaced micro LED 2′ is not soldered with the contact pad, it falls off the target substrate TS. - Referring to
FIG. 6D , in target regions missing micro LEDs, a replacement micro LED 2″ with adense metal block 90 may be transferred, e.g., individually transferred, onto the target substrate TS. - Referring to
FIG. 6E , the target substrate TS is heated again to convert thedense metal block 90 of the replacement micro LEDs 2″ into abonding pad 70, and thebonding pad 70 is soldered with the contact pad CP. Thebonding pad 70 is in direct contact with thefirst electrode 20 of the replacement micro LEDs 2″ and is between thefirst electrode 20 and the target substrate TS. - Referring to
FIG. 6F , the method in some embodiments further includes forming an insulatinglayer 6 on the plurality of micro LEDs 2; and acommon electrode layer 7 on a side of the insulatinglayer 6 away from the plurality of micro LEDs 2. In one example, the target substrate TS is a thin film transistor array substrate. Optionally, as shown inFIG. 5N , thecommon electrode layer 7 is a unitary layer electrically connected to the respective one of the plurality of micro light emitting diodes 2. - In another aspect, the present disclosure provides a display apparatus having the array substrate described herein or fabricated by a method described herein, or having the micro light emitting diode described herein or fabricated by a method described herein. Optionally, the display apparatus further includes one or more integrated circuits connected to the array substrate. Examples of appropriate display apparatuses include, but are not limited to, an electronic paper, a mobile phone, a tablet computer, a television, a monitor, a notebook computer, a digital album, a GPS, etc.
- The foregoing description of the embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or to exemplary embodiments disclosed. Accordingly, the foregoing description should be regarded as illustrative rather than restrictive. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. The embodiments are chosen and described in order to explain the principles of the invention and its best mode practical application, thereby to enable persons skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use or implementation contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents in which all terms are meant in their broadest reasonable sense unless otherwise indicated. Therefore, the term “the invention”, “the present invention” or the like does not necessarily limit the claim scope to a specific embodiment, and the reference to exemplary embodiments of the invention does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is limited only by the spirit and scope of the appended claims. Moreover, these claims may refer to use “first”, “second”, etc, following with noun or element. Such terms should be understood as a nomenclature and should not be construed as giving the limitation on the number of the elements modified by such nomenclature unless specific number has been given. Any advantages and benefits described may not apply to all embodiments of the invention. It should be appreciated that variations may be made in the embodiments described by persons skilled in the art without departing from the scope of the present invention as defined by the following claims. Moreover, no element and component in the present disclosure is intended to be dedicated to the public regardless of whether the element or component is explicitly recited in the following claims.
Claims (22)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/CN2019/092301 WO2020252776A1 (en) | 2019-06-21 | 2019-06-21 | Micro light emitting diode, array substrate, display apparatus, and method of fabricating array substrate |
Publications (1)
Publication Number | Publication Date |
---|---|
US20220037555A1 true US20220037555A1 (en) | 2022-02-03 |
Family
ID=74039983
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/762,922 Abandoned US20220037555A1 (en) | 2019-06-21 | 2019-06-21 | Micro light emitting diode, array substrate, display apparatus, and method of fabricating array substrate |
Country Status (3)
Country | Link |
---|---|
US (1) | US20220037555A1 (en) |
CN (1) | CN112424941B (en) |
WO (1) | WO2020252776A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114242864B (en) * | 2021-12-15 | 2023-11-24 | 厦门天马微电子有限公司 | Micro light emitting diode, display substrate, manufacturing method of display substrate and display device |
WO2023142144A1 (en) * | 2022-01-31 | 2023-08-03 | Jade Bird Display (Shanghai) Company | Micro led structure and micro display panel |
WO2023164899A1 (en) * | 2022-03-03 | 2023-09-07 | Jade Bird Display (Shanghai) Company | Micro led, micro led panel and micro led chip |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102576783A (en) * | 2009-07-30 | 2012-07-11 | 3M创新有限公司 | Pixelated led |
US8426227B1 (en) * | 2011-11-18 | 2013-04-23 | LuxVue Technology Corporation | Method of forming a micro light emitting diode array |
US9178123B2 (en) * | 2012-12-10 | 2015-11-03 | LuxVue Technology Corporation | Light emitting device reflective bank structure |
US10217403B2 (en) * | 2016-05-20 | 2019-02-26 | Innolux Corporation | Display apparatus |
CN108666337B (en) * | 2017-03-27 | 2021-12-14 | 英属开曼群岛商錼创科技股份有限公司 | Micro light-emitting diode and display panel |
CN107331680B (en) * | 2017-07-05 | 2020-04-24 | 上海天马微电子有限公司 | Display panel, manufacturing method thereof and display device |
US10020422B1 (en) * | 2017-09-29 | 2018-07-10 | Oculus Vr, Llc | Mesa shaped micro light emitting diode with bottom N-contact |
US10707266B2 (en) * | 2017-11-23 | 2020-07-07 | Century Micro Display Technology (Shenzhen) Co., Ltd. | Micro LED display panel with double-sides display |
CN109817109A (en) * | 2019-03-29 | 2019-05-28 | 上海天马微电子有限公司 | A kind of display panel and display device |
-
2019
- 2019-06-21 WO PCT/CN2019/092301 patent/WO2020252776A1/en active Application Filing
- 2019-06-21 CN CN201980000887.5A patent/CN112424941B/en active Active
- 2019-06-21 US US16/762,922 patent/US20220037555A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
WO2020252776A1 (en) | 2020-12-24 |
CN112424941B (en) | 2024-02-20 |
CN112424941A (en) | 2021-02-26 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US10312225B2 (en) | Display apparatus and manufacturing method thereof | |
US20220037555A1 (en) | Micro light emitting diode, array substrate, display apparatus, and method of fabricating array substrate | |
US11282980B2 (en) | Method of fabricating a micro light emitting diode display substrate, and micro light emitting diode display substrate | |
US11251341B2 (en) | Micro light emitting diode display panel, micro light emitting diode display apparatus, and method of fabricating micro light emitting diode display panel | |
JP5206923B2 (en) | Semiconductor light emitting device | |
US8134169B2 (en) | Patterned substrate for hetero-epitaxial growth of group-III nitride film | |
US20180206299A1 (en) | Micro led display device | |
WO2018018895A1 (en) | Oled array substrate and method for manufacturing same, and oled display panel | |
US20140027802A1 (en) | Light emitting diode with undercut and manufacturing method thereof | |
US20220189814A1 (en) | Method of manufacturing display device and display device | |
US20170250315A1 (en) | Dot matrix light-emitting diode backlighting light source for a wafer-level microdisplay and method for fabricating the same | |
US10411159B2 (en) | Patterned substrate and light emitting diode wafer | |
CN116504898A (en) | Nanorod light emitting diode, display device including the same, and method of manufacturing the same | |
US20230106020A1 (en) | Light-emitting diode chip and method for manufacturing the same | |
KR102100749B1 (en) | Semiconductor light emitting device and method of manufacturing the same | |
KR102089499B1 (en) | Semiconductor light emitting device and method of manufacturing the same | |
US11309468B2 (en) | Method of fabricating micro light emitting diode array substrate, micro light emitting diode array substrate, micro light emitting diode display apparatus | |
CN110993761A (en) | Active matrix colour display device | |
US20230299055A1 (en) | Substrate for manufacturing display device, and method for manufacturing display device by using same | |
US11742457B2 (en) | Electronic device and manufacturing method thereof | |
KR102134239B1 (en) | Semiconductor light emitting device and method of manufacturing the same | |
US11984531B2 (en) | Light emitting device and wafer | |
US20230197693A1 (en) | Micro led display apparatus and method of manufacturing the same | |
TW202005137A (en) | Micro-component fabrication process and method for producing display panel | |
CN112185989A (en) | Structure and manufacturing method of inorganic light-emitting diode display device |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: BOE TECHNOLOGY GROUP CO., LTD., CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WANG, YANGPENG;REEL/FRAME:052859/0906 Effective date: 20200507 Owner name: CHENGDU BOE OPTOELECTRONICS TECHNOLOGY CO., LTD., CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WANG, YANGPENG;REEL/FRAME:052859/0906 Effective date: 20200507 Owner name: BOE TECHNOLOGY GROUP CO., LTD., CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ZHANG, ZHENHUA;REEL/FRAME:052859/0873 Effective date: 20200507 Owner name: CHENGDU BOE OPTOELECTRONICS TECHNOLOGY CO., LTD., CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ZHANG, ZHENHUA;REEL/FRAME:052859/0873 Effective date: 20200507 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |